Non-polluting combustion engine having ultrasonic fuel atomizer in place of carburetor

ABSTRACT

A combustion engine includes a powerful unltrasonic fuel atomizer connected to the intake manifold thereof instead of a carburetor. The ultrasonic fuel atomizer includes a horizontal atomizing chamber, having a fuel inlet at the top and a fuel tray at the bottom. A powerful ultrasonic ferrite vibrator has the large end of an exponential horn mounted thereon, the small end of the horn extending into the chamber to a position under the fuel inlet and above the tray. An air inlet is provided in the chamber around the small end of the exponential horn, and the end of the chamber toward which the small end of the horn faces is connected to the intake manifold of the internal combustion engine. A constant and excessive quantity of fuel fed to the fuel inlet streams down from the inlet and is fully atomized while pouring over the ultrasonically vibrating head of the exponential horn. Fuel not sucked into the engine through the intake manifold thereof is collected in the fuel tray and recirculated to be again fed to the fuel inlet.

United States Patent [151 Sata [ NON-POLLUTING COMBUSTION ENGINE HAVINGULTRASONIC FUEL ATOMIZER IN PLACE OF CARBURETOR [76] Inventor: NaoyasuSata, 8O Yamate Machi,

Ashiya, Japan 221 Filed: Mar. 27, 1974 21 Appl. No.: 455,350

Related US. Application Data [63] Continuation-impart of Ser. No.187,950, Oct. 12,

1971, abandoned.

[30] Foreign Application Priority Data Dec. 21, 1970 Japan 45-11410 [52]US. Cl 239/102, 239/338, 239/416.5 [51] Int. Cl B05b 17/06 [58] Field ofSearch 239/102, 120, 121, 337, 239/338, 416.5, 424

[56] References Cited UNITED STATES PATENTS 3,392,916 7/1968 Engstriimet al 239/102 3,784,105 1/1974 Goodinge et al. 239/102 3,796,536 3/1974I-Iori et a1 239/102 Jan. 14, 1975 Primary Examiner-M. Henson Wood, Jr.Assistant Examiner-Michael Mar Attorney, Agent, or FirmWenderoth, Lind &Ponack [57] ABSTRACT A combustion engine includes a powerful unltrasonicfuel atomizer connected to the intake manifold thereof instead of acarburetor. The ultrasonic fuel atomizer includes a horizontal atomizingchamber, having a fuel inlet at the topand a fuel tray at the bottom. Apowerful ultrasonic ferrite vibrator has the large end of an exponentialhorn mounted thereon, the small end of the horn extending into thechamber to a position under the fuel inlet and above the tray. An airinlet is provided in the chamber around the small end of the exponentialhorn, and the end of the chamber toward which the small end of the hornfaces is connected to the intake manifold of the internal combustionengine. A constant and excessive quantity of fuel fed to the fuel inletstreams down from the inlet and is fully atomized while pouring over theultrasonically vibrating head of the exponential horn. Fuel not suckedinto the engine through the intake manifold thereof is collected in thefuel tray and recirculated to be again fed to the fuel inlet.

6 Claims, 1 Drawing Figure NON-POLLUTING COMBUSTION ENGINE HAVINGULTRASONIC FUEL ATOMIZER IN PLACE OF CARBURETOR This application is acontinuation-in-part of copending application Ser. No. 187,950, filedOct. 12, 1971 now abandoned.

BACKGROUND OF THE INVENTION This invention relates to an internalcombustion engine having a fuel atomizer in place of a carburetor, andmore particularly to such a combination in which liquid fuel is atomizedby ultrasonic energy.

Over forty years have elapsed since the introduction of high powerultrasonic vibrations produced by the piezoelectric effect from crystalssuch as quartz, and later from a ferrite core by the magneto-strictiveeffect. During this time it has been proposed to use ultrasonicvibrations for the breaking up of microbes such as colon bacilli andcancer cells, the dispersing of oil in liquids to make an emulsion andthe dispersing or atomizing of liquid fuel oil in air. Such applicationsof the intensive ultrasonic waves by piezoelectric and magneto-strictiveeffects have been most intensively explored by the researchers in themany scientific fields all over the world.

The conventional carburetor, assumed to be indispensable in an internalcombustion engine, employs the principle of an atomizer making use ofthe vacuum developed in a venturi tube by the suction stroke of a pistonof the engine. In this orthodox type of carburetor the fuel is atomizedto form small droplets in air and is expected to burn sufficiently wellfor good engine performance. However, sometimes the burning orcombustion of the fuel creates noxious fumes which result in airpollution.

The ultrasonic vibrations described above are also useful for atomizingfuel, and when an ultrasonic atomizer is used it is theoretically andexperimentally verified that the size of fuel droplets is very muchfiner than those produced by the venturi atomizer or carburetor. Thus anultrasonic atomizer seems, from a qualitative standpoint, to beremarkably more efficient than an ordinary carburetor. However, untilnow the amount of fuel which can be atomized by such an ordinaryultrasonic vibrator was quantitatively not sufficient for use in anautomobile replacing the carburetor.

Also, in previously known ultrasonic atomizers, in order to have anatomizing capacity sufficient for the fuel needs of an automobileengine, the ultrasonic wave generator to drive an ultrasonic transducerwould weigh at least over 100 Kgs.

It has thus not heretofore been considered to be practicable tocompletely replace the standard carburetor with an ultrasonic atomizer.Consequently, many attempts have been made in recent years to use suchan atomizer together with the known venturi atomizer in a carburetor inorder to attain atomization of a sufficient quantity of fuel forautomobile use.

It has now been found that a very powerful ultrasonic vibrator can bemade by attaching an exponential horn to a ferrite ultrasonictransducer, which is a magnetostrictive type of ultrasonic vibrator,which greatly magnifies the vibration energy. This type of vibrator canatomize the great amount of fuel needed for an automobile. Also, theweight of such ultrasonic generator is decreased enormously by therecent invention of power transistor and other diode accessories.

SUMMARY OF THE INVENTION It is the object of the present invention toprovide an engine including a fuel atomizing device which utilizesultrasonic vibrations to independently atomize sufficient fuel for aninternal combustion engine and to completely replace the standardcarburetor with such an atomizer.

It is a further object and fundamental principle of the presentinvention, and having succeeded in actual tests, to employ the recentlydeveloped light weight power transistor ultrasonic wave generator todrive the ferrite transducer of the atomizer, whereby the entire unit issufficiently light in weight to be employable in standard vehicles.

It is also an important object of the present invention to provide suchan ultrasonic atomizer engine whereby consumption of the fuel is greatlydecreased over previous engines, thereby eliminating a serious source ofair pollution.

To this end the present invention provides an engine and a fuel atomizerwhich comprises a horizontal atomizing chamber connected to the engineintake manifold with a fuel inlet at the top, a fuel tray at the bottomand in the middle a powerful ferrite or the like ultrasonic vibrator.Since all of the elements are arranged horizontally, the inventionresults in a low, compact unit which can easily be fitted into thelimited space of the engine area of an automobile body. In the atomixingchamber liquid fuel streams down from the inlet and is atomized as itpours over the head of the vibrator, while the fuel which is not suckedinto the intake manifold or not atomized is collected itself in the trayand pumped from the tray up to the fuel tank and is recirculated.

BRIEF DESCRIPTION OF THE DRAWING One example of the invention will bedescribed with reference to the attached drawing which is a schematicview, partly in section, of the fuel atomizer and engine according tothe invention.

DETAILED DESCRIPTION OF THE INVENTION In the drawing, a fuel atomizingchamber 1 is connected to the air intake manifold 2 of an internalcombustion engine A, such as a 4-cylinder automobile gasoline engine. Afuel inlet 3 is provided at the top of chamber 1 and fuei tray 4 forcollecting excessive fuel is provided at the bottom beneath inlet 3. Thefuel inlet 3 is connected to a fuel tank 5 by a pipe 6 and fuel tray 4opens into a pipe 7 which leads to the suction side of a fuel pump 8. Apipe extends from the discharge side of pump 8 to the fuel tank 5.

To a powerful ferrite ultrasonic vibrator I0 is attached the large endof an exponential horn 9 so as to emit ultrasonic vibration by anelectric power source 11 which is tuned to a constant maximum output.The small end of horn 9 extends horizontally into the atomixing chamber1, with the free vibrating end facing toward the air intake manifold 2of the engine. In the end of chamber 1 oipposite to the engine is fittedan iris-shaped vane-type air intake valve 12 around the exponential horn9 by which the necessary amount of air sucked in and mixed with theatomized fuel in chamber 1 is controlled. Air valve 12 is controlled bylever 14 which is linked to accelerator pedal 15 of the engine 2 just asby the conventional carburetor throttle control. A nozzle 13 on the fuelinlet 3 directly faces the vibrat- 3 nafr seyiqfhqm 91th? an l between ew i easily adjustable for the highest fuel atomizing efficiency. Fuelpump 8 must have ample capacity to pump an amount of fuel in excess torecirculate the fuel from tray 4 to tank 5 through pipe 7.

The operation is as follows: when the fuel from nozzle 13 constantlypours on the vibrating free end of the horn 9, fuel is instantlyatomized. Then, by pushing the starter button of the engine and at thesame time slowly opening air inlet valve 12 by pushing the acceleratorpedal 15, the gasoline mist in atomization chamber 1 is mixed with airand sucked through manifold 2 into the combustion chamber of the engine.Thus, the engine starts at once. By providing maximum output of thetuned vibration head of exponential horn 9, the atomization chamber 1 isalways constantly filled with atomized gasoline. Therefore, the enginespeed is regulated only by accelerating pedal 15, which is linked withair intake valve lever 14, just as in a carburator engine. Thus theultrasonic atomizer totally replaces the conventional venturi typecarburetor. Due to its ingenious but simple construction, the ultrasonicatomizer engine of the present invention can be operated quite simply,economically and without danger of failure. Furthermore, this ultrasonicatomizer is widely adjustable and yet accurate to all liquid fuelrequirement conditions. The efficiency of fuel combustion of the engineemploying this atomizer will be almost 100 percent because the fuel isatomized to an extremely fine mist, and this accordingly reduceshydrocarbons and carbon monoxide concentration in the exhaust gas, thusreducing pollution of the atmosphere. This advantage is very significanttoday in view of the severe MASKY- regulations.

In carrying out the present invention, it has been possible to fabricatean atomizer including ultrasonic generator l1, vibrator l0 and horn 9weighing less than Kgs and haviong a gasoline atomizing capacity of over20 Liters per hour.

Various specific features of the invention, such as power requirementsof source 11, the specific frequency of vibration of horn 9, precisesize of horn 9, size of chamber 1 and inlet 3 etc. have not beendescribed in detail, but'it will be apparent that those skilled in theart would readily be able to determine such features for any given sizeand type of engine. Such features may be very easily calculated anddesigned from the 'data published under the title Liquid Atomization byUltrasonic Vibration by Hirose and Kimoto [Journ. Soc. Acoustic, Japan,Vol. 28, No. 7, p. 335.(l972)].

I claim:

1. A non-carburetor-type internal combustion engine system comprising:

an intake manifold; and

ultrasonic atomizer means for supplying atomized fuel to said intakemanifold, said ultrasonic atomizer means comprising:

a horizontal atomizing chamber connected at one end thereof to saidintake manifold;

an ultrasonic ferrite transducer;

an'exponentially shaped resonator having the large end thereof attachedto said transducer and the small end thereof having a vibrating headthereon and extending into said atomizing chamber and facing said oneend of said atomizing chamber connected to said intake manifold;

a lightweight, power transistor ultrasonic wave generator means attachedto said ultrasonic ferrite transducer for imparting vibrations thereto;

fuel inlet means extending through the top of said atomizing chamber toa position directly above said vibrating head for supplying a constantamount, greater than required by said engine, of fuel to said vibratinghead, whereby the thus supplied fuel contacts said vibrating head and isfully atomized thereby;

air inlet means in said chamber for allowing passage therein of air tomix with said atomized fuel and to pass therewith into said intakemanifold; and

fuel tray means in the bottom of said atomizing chamber at a positionbelow said vibrating head for receiving fuel not sucked into said intakemanifold.

2. An engine system as claimed in claim 1, further comprising a fuelsupply tank connected to said fuel inlet means; conduit means connectingsaid fuel tray means with said fuel supply tank; and pump means in saidconduit means for recirculating said fuel from said fuel tray means backto said fuel supply tank.

3. An engine system as claimed in claim 1, wherein said air inlet meansextends into said atomizing chamber at an end thereof opposite said endthereof connected to said intake manifold, said air inlet meanscomprising adjustable valve means for controlling the amount of airentering said atomizing chamber.

4. In a non-carburetor-type internal combustion engine including anintake manifold and fuel supply means for supplying fuel to said intakemanifold, the improvement wherein said fuel supply means com prises anultrasonic atomizer means, in place of a conventional carburetor, forsupplying atomized fuel to said intake manifold, said ultrasonicatomizer means comprising:

a horizontal atomizing chamber connected at one end thereof to saidintake manifold;

an ultrasonic ferrite transducer;

an exponentially shaped resonator having the large end thereof attachedto said transducer and the small end thereof having a vibrating headthereon and extending into said atomizing chamber and facing said oneend of said atomizing chamber connected to said intake manifold;

fuel inlet means extending through the top of said atomizing chamber toa position directly above said vibrating head for supplying a constantamount, greater than required by said engine, of fuel to said vibratinghead, whereby the thus supplied fuel contacts said vibrating head and isfully atomized thereby;

air inlet means in said chamber for allowing passage therein of air tomix with said atomized fuel and to pass therewith into said intakemanifold; and

fuel tray means in the bottom of said atomizing chamber at a positionbelow said vibrating head for receiving fuel not sucked into said intakemanifold.

5. The improvement of claim 4, further comprising a fuel supply tankconnected to said fuel inlet means; conduit means connecting said fueltray means with said fuel supply tank; and pump means in said conduitmeans for recirculating said fuel from said fuel tray means back to saidfuel supply tank.

6. The improvement of claim 4, wherein said air inlet means extends intosaid atomizing chamber at an end thereof opposite said end thereofconnected to said intake manifold, said air inlet means comprisingadjustable valve means for controlling the amount of air entering saidatomizing chamber.

1. A non-carburetor-type internal combustion engine system comprising:an intake manifold; and ultrasonic atomizer means for supplying atomizedfuel to said intake manifold, said ultrasonic atomizer means comprising:a horizontal atomizing chamber connected at one end thereof to saidintake manifold; an ultrasonic ferrite transducer; an exponentiallyshaped resonator having the large end thereof attached to saidtransducer and the small end thereof having a vibrating head thereon andextending into said atomizing chamber and facing said one end of saidatomizing chamber connected to said intake manifold; a lightweight,power transistor ultrasonic wave generator means attached to saidultrasonic ferrite transducer for imparting vibrations thereto; fuelinlet means extending through the top of said atomizing chamber to aposition directly above said vibrating head for supplying a constantamount, greater than required by said engine, of fuel to said vibratinghead, whereby the thus supplied fuel contacts said vibrating head and isfully atomized thereby; air inlet means in said chamber for allowingpassage therein of air to mix with said atomized fuel and to passtherewith into said intake manifold; and fuel tray means in the bottomof said atomizing chamber at a position below said vibrating head forreceiving fuel not sucked into said intake manifold.
 2. An engine systemas claimed in claim 1, further comprising a fuel supply tank connectedto said fuel inlet means; conduit means connecting said fuel tray meanswith said fuel supply tank; and pump means in said conduit means forrecirculating said fuel from said fuel tray means back to said fuelsupply tank.
 3. An engine system as claimed in claim 1, wherein said airinlet means extends into said atomizing chamber at an end thereofopposite said end thereof connected to said intake manifold, said airinlet means comprising adjustable valve means for controlling the amountof air entering said atomizing chamber.
 4. In a non-carburetor-typeinternal combustion engine including an intake manifold and fuel supplymeans for supplying fuel to said intake manifold, the improvementwherein said fuel supply means comprises an ultrasonic atomizer means,in place of a conventional carburetor, for supplying atomized fuel tosaid intake manifold, said ultrasonic atomizer means comprising: ahorizontal atomizing chamber connected at one end thereof to said intakemanifold; an ultrasonic ferrite transducer; an exponentially shapedresonator having the large end thereof attached to said transducer andthe small end thereof having a vibrating head thereon and extending intosaid atomizing chamber and facing said one end of said atomizing chamberconnected to said intake manifold; fuel inlet means extending throughthe top of said atomizing chamber to a position directly above saidvibrating head for supplying a constant amount, greater than required bysaid engine, of fuel to said vibrating head, whereby the thus suppliedfuel contacts said vibrating head and is fully atomized thereby; airinlet means in said chamber for allowing passage therein of air to mixwith said atomized fuel and to pass therewith into said intake manifold;and fuel tray means in the bottom of said atomizing chamber at aposition below said vibrating head for receiving fuel not sucked intosaid intake manifold.
 5. The improvement of claim 4, further comprisinga fuel supply tank connected to said fuel inlet means; conduit meansconnecting said fuel tray means with said fuel supply tank; and pumpmeans in said conduit means for recirculating said fuel from said fueltray means back to said fuel supply tank.
 6. The improvement of claim 4,wherein said air inlet means extends into said atomizing chamber at anend thereof opposite said end thereof connected to said intake manifold,said air inlet means comprising adjustable valve means for controllingthe amount of air entering said atomizing chamber.